US8179013B2 - Stator for dynamoelectric machine and method of manufacturing same - Google Patents

Stator for dynamoelectric machine and method of manufacturing same Download PDF

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Publication number
US8179013B2
US8179013B2 US12/613,782 US61378209A US8179013B2 US 8179013 B2 US8179013 B2 US 8179013B2 US 61378209 A US61378209 A US 61378209A US 8179013 B2 US8179013 B2 US 8179013B2
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stator
stator core
electric wires
oblique
set forth
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US20100117480A1 (en
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Atsuo Ishizuka
Tetsuya Gorohata
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Denso Corp
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Denso Corp
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    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
    • H02K3/28—Layout of windings or of connections between windings
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/0025—Shaping or compacting conductors or winding heads after the installation of the winding in the core or machine ; Applying fastening means on winding heads
    • H02K15/0037—Shaping or compacting winding heads
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K15/00—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines
    • H02K15/04—Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of windings, prior to mounting into machines
    • H02K15/0435—Wound windings
    • H02K15/0478—Wave windings, undulated windings
    • H—ELECTRICITY
    • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
    • H02K—DYNAMO-ELECTRIC MACHINES
    • H02K3/00—Details of windings
    • H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
    • H02K3/12—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors arranged in slots
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49002—Electrical device making
    • Y10T29/49009—Dynamoelectric machine

Definitions

  • the present invention relates to stators for dynamoelectric machines that are used in, for example, motor vehicles as electric motors and electric generators, and methods of manufacturing the stators.
  • a dynamoelectric machine such as an electric motor and an electric generator, generally includes a rotor, a stator, and a housing that accommodates both the rotor and the stator.
  • the rotor is fixed on a rotating shaft that is rotatably supported by the housing.
  • the stator is fixed in the housing so as to surround the radially outer periphery of the rotor.
  • the stator includes a hollow cylindrical stator core and a stator coil mounted on the stator core.
  • the stator core has a plurality of slots that are formed in a radially inner surface of the stator core and spaced in the circumferential direction of the stator core at predetermined intervals.
  • the stator coil is made up of a plurality of electric wires mounted on the stator core.
  • Each of the electric wires includes a plurality of in-slot portions, which are received in the slots of the stator core, and a plurality of connecting portions that are located outside of the slots to connect the in-slot portions.
  • the above stator coil can be formed with a flat band-shaped electric wire assembly that is manufactured by a conventional method disclosed in, for example, Japanese Patent First Publication No. 2004-104841.
  • a plurality of electric wires are first formed to have a triangular-wave shape. Then, one of the electric wires is held stationary, and the other electric wires are sequentially woven onto the stationary electric wire to form the flat band-shaped electric wire assembly. More specifically, in the weaving step, each of the other electric wires is repeatedly rotated about its axis by 90° and moved toward the stationary electric wire by a half of its pitch.
  • the flat electric wire assembly may be rolled by a predetermined number of turns to form a hollow cylindrical electric wire assembly.
  • a plurality of stator core pieces may be mounted to the hollow cylindrical electric wire assembly.
  • the stator core pieces may be joined together, forming the stator in which the hollow cylindrical electric wire assembly makes up the stator coil and the stator core pieces together make up the stator core.
  • the axial end portions of the stator coil which are made up of the connecting portions of the electric wires, protrude from the axial end faces of the stator core.
  • the axial end portions of the stator coil will be referred to as coil ends of the stator coil. Since each of the connecting portions of the electric wires extends to form the shape of a triangle, the axial end faces of the coil ends become uneven in the extending directions of the connecting portions. Moreover, each of the connecting portions of the electric wires has an apex which is axially furthest in the connecting portion from the stator core.
  • the apexes of the connecting portions are circumferentially spaced away from each other by the distance between each circumferentially-adjacent pair of the slots of the stator core. Consequently, the apexes of all the connecting portions of the electric wires together form a plurality of curved ridges, each of which extends obliquely from the radially inner side to the radially outer side of the stator coil, with a plurality of valleys formed between the ridges.
  • a coolant e.g., ATF
  • ATF a coolant supplied to flow along the surfaces of the coil ends and the stator core, thereby cooling the stator coil and the stator core.
  • the coolant flows, with rotation of the rotor of the dynamoelectric machine, from the radially inner side to the radially outer side of the stator core 60 A, thereby cooling the axial end faces of the coil ends of the stator coil 70 A.
  • stator coil formed with the flat band-shaped electric wire assembly manufactured by the conventional method the flow of the coolant passing the axial end face of one of the coil ends is different from that passing the axial end face of the other coil end.
  • the extending directions of the ridges 700 A which are made up of the apexes of the connecting portions of the electric wires, are coincident with the rotating direction b of the rotor 40 A and thus also coincident with the flow direction of the coolant.
  • the coolant can smoothly flow along the axial end face of the coil end from the radially inner side to the radially outer side of the stator core 60 A, thereby effectively cooling the coil end.
  • the extending directions of the ridges 700 A are transverse to the rotating direction b of the rotor 40 A and thus also transverse to the flow direction of the coolant. It should be noted that for the sake of simplicity, only one of the ridges 700 A is indicated with a solid line in FIG. 19B . Consequently, the coolant cannot smoothly flow along the axial end face of the other coil end, thereby failing to effectively cool the other coil end.
  • a stator for a dynamoelectric machine which includes a hollow cylindrical stator core and a stator coil.
  • the stator core has a plurality of slots that are formed in a radially inner surface of the stator core and spaced at predetermined intervals in the circumferential direction of the stator core.
  • the stator coil is made up of a plurality of wave-shaped electric wires mounted on the stator core.
  • Each of the electric wires has a plurality of in-slot portions, each of which is received in one of the slots of the stator core, and a plurality of connecting portions each of which is located outside of the slots of the stator core to connect one adjacent pair of the in-slot portions of the electric wire.
  • Each of the connecting portions includes an apex part that is located axially furthest in the connecting portion from the stator core and includes an oblique section; the oblique section extends obliquely with respect to the radial direction of the stator core, Further, in the stator according to the invention, the oblique sections of the apex parts of the connecting portions of the electric wires located on one axial side of the stator core are oblique in the same direction as those located on the other axial side of the stator core.
  • the flow path of the coolant provided on the axial end face of the stator coil on one side of the stator core is identical to that provided on the axial end face of the stator coil on the other side of the stator core.
  • the oblique angles of the oblique sections of the apex parts of the connecting portions increase from the radially inner side to the radially outer side of the stator core.
  • the oblique angles of the oblique sections of the electric wires which fall on the same circle are equal to each other.
  • Each of the connecting portions of the electric wires is stepped to include a plurality of shoulder parts that extend parallel to an axial end face of the stator core from which the connecting portion protrudes. Further, the plurality of shoulder parts include two shoulder parts each of which is adjacent to one of the pair of in-slot portions connected by the connecting portion. There is specified the following dimensional relationship: d1 ⁇ d2, where d1 is the length of each of the two shoulder parts adjacent to the in-slot portions, and d2 is the distance between each circumferentially-adjacent pair of the slots of the stator core.
  • the change in radial position of the electric wire caused by one of the oblique sections of the electric wire is substantially equal to the thickness of the electric wire.
  • Each of the electric wires is made up of an electric conductor having a rectangular cross section and an insulating coat covering the surface of the electric conductor.
  • the insulating coat is two-layer structured to include an inner layer and an outer layer.
  • the inner layer has a higher glass transition temperature than the outer layer.
  • a method of manufacturing the stator according to the invention includes the steps of: (1) preparing a plurality of electric wires and a plurality of stator core pieces that together make up the stator core; (2) shaping the electric wires to obtain the plurality of wave-shaped electric wires; (3) stacking the wave-shaped electric wires to form a flat band-shaped electric wire assembly; (4) rolling the flat band-shaped electric wire assembly by a predetermined number of turns to form the stator coil which has a hollow cylindrical shape; and (5) assembling the stator core pieces to the stator coil to form the stator.
  • this other method includes the steps of: (1) preparing a plurality of electric wires and a plurality of stator core pieces that together make up the stator core; (2) shaping the electric wires to obtain the plurality of wave-shaped electric wires, wherein the plurality of wave-shaped electric wires are classified into a plurality of groups so that the wave-shaped electric wires in the same group have the same length, but those in different groups have different lengths; (3) stacking the wave-shaped electric wires in groups to form a plurality of flat band-shaped electric wire assemblies which have different lengths; (4) rolling the flat band-shaped electric wire assemblies separately by a single turn to form a plurality of hollow cylindrical electric wire assemblies which have different inner and outer diameters; (5) assembling the hollow cylindrical electric wire assemblies to form the stator coil; and (6) assembling the stator core pieces to the stator coil to form the stator.
  • FIG. 1 is a schematic cross-sectional view showing the overall configuration of a dynamoelectric machine which includes a stator according to the first embodiment of the invention
  • FIG. 2 is an end view of the stator
  • FIG. 3 is an end view of a stator core of the stator
  • FIG. 4 is an end view of one of stator core pieces which together make up the stator core
  • FIGS. 5A-5C are respectively a rear end view, a top view, and a front end view of one of electric wires which together make up a stator coil of the stator;
  • FIG. 6 is a perspective view showing a connecting portion of one of the electric wires
  • FIGS. 7A-7C are respectively a rear end view, a top view, and a front end view of one of electric wires for forming a stator coil using a conventional method
  • FIG. 8 is a schematic view showing oblique sections provided in the electric wires for forming the stator coil according to the first embodiment
  • FIG. 9A is a cross-sectional view illustrating the configuration of the electric wires for forming the stator coil according to the first embodiment
  • FIG. 9B is a cross-sectional view illustrating a modification of the configuration of the electric wires shown in FIG. 9A ;
  • FIG. 10 is a schematic circuit diagram of the stator according to the first embodiment
  • FIGS. 11A-11C , 12 A- 12 C, 13 A- 13 C, and 14 A- 14 C are schematic views illustrating an electric wire assembly-forming step in manufacturing the stator according to the first embodiment
  • FIG. 15A is a schematic end view illustrating the flow path of a coolant on the axial end face of the stator coil one side of the stator core according to the first embodiment
  • FIG. 15B is a schematic end view illustrating the flow path of the coolant on the axial end face of the stator coil on the other side of the stator core according to the first embodiment
  • FIGS. 16A-16D are perspective views showing hollow cylindrical electric wire assemblies for forming a stator coil according to the second embodiment of the invention.
  • FIG. 17 is a perspective view showing the stator coil according to the second embodiment.
  • FIG. 18 is a schematic perspective view illustrating the flow of a coolant through a conventional stator
  • FIG. 19A is a schematic end view illustrating the flow path of the coolant on one axial side of the conventional stator.
  • FIG. 19B is a schematic end view illustrating the flow path of the coolant on the other axial side of the conventional stator.
  • FIGS. 1-17 Preferred embodiments of the present invention will be described hereinafter with reference to FIGS. 1-17 . It should be noted that, for the sake of clarity and understanding, identical components having identical functions in different embodiments of the invention have been marked, where possible, with the same reference numerals in each of the figures.
  • FIG. 1 shows the overall configuration of a dynamoelectric machine 100 which includes a stator 50 according to the first embodiment of the invention.
  • the dynamoelectric machine 100 is configured to function as either an electric generator or an electric motor in a motor vehicle, such as an electric vehicle or a hybrid vehicle.
  • the dynamoelectric machine 100 further includes a housing 20 and a rotor 40 in addition to the stator 50 .
  • the housing 20 is composed of a pair of cup-shaped housing pieces 21 and 22 which are jointed together at the open ends thereof.
  • the housing 20 has a pair of bearings 31 and 32 mounted therein, via which a rotating shaft 30 is rotatably supported by the housing 20 .
  • the rotor 40 is received in the housing 20 and fixed on the rotating shaft 30 .
  • the stator 50 is fixed in the housing 20 so as to surround the radially outer periphery of the rotor 40 .
  • the rotor 40 includes a permanent magnet that is provided on a radially outer periphery of the rotor 40 facing a radially inner periphery of the stator 50 .
  • the permanent magnet has formed therein a plurality of magnetic poles that are arranged in the circumferential direction of the rotating shaft 30 at predetermined intervals.
  • the magnetic poles are so magnetized that the polarities of the magnetic poles alternate between N (North) and S (South) in the circumferential direction of the rotating shaft 30 .
  • the number of the magnetic poles is dependent on the type of the dynamoelectric machine 100 . In the present embodiment, the number of the magnetic poles is set to eight (i.e., four N poles and four S poles).
  • the stator 50 includes, as shown in FIGS. 1-3 , a hollow cylindrical stator core 60 and a three-phase stator coil 70 mounted on the stator core 60 .
  • the stator core 60 has a plurality of slots 61 that are formed in the radially inner surface of the stator core 60 and spaced in the circumferential direction of the stator core 60 at predetermined intervals.
  • the stator coil 70 has a plurality of in-slot portions received in the slots 61 of the stator core 60 and an opposite pair of axial end portions respectively protruding from the axial end faces of the stator core 60 .
  • the axial end portions of the stator coil 70 will be referred to as coil ends of the stator coil 70 .
  • the stator 50 may further include an insulating paper interposed between the stator core 60 and the stator coil 70 . The detailed configuration of the stator 50 will be described later.
  • the dynamoelectric machine 100 further includes a coolant supplier (not shown), a coolant collector (not shown), and a coolant recirculator (not shown).
  • the coolant supplier supplies a coolant for cooling both the rotor 40 and the stator 50 from the outside to the inside of the housing 20 via coolant pipes 23 .
  • the dynamoelectric machine 100 actually includes at least two coolant pipes 23 that are respectively axially located on opposite sides of the stator 50 . As shown in FIG. 1 , each of the coolant pipes 23 extends through an axial end wall of the housing 20 to have an open end thereof located vertically upward of a corresponding one of the coil ends of the stator coil 70 .
  • each of the coolant pipes 23 there is formed a coolant discharge outlet 23 a through which the coolant is discharged into the inside of the housing 20 .
  • the coolant collector collects the coolant discharged into the inside of the housing 20 .
  • the coolant recirculator recirculates the coolant collected by the coolant collector back to the coolant supplier.
  • ATF Automotive Transmission Fluid
  • other conventional coolants such as cooling oil, may also be used instead of ATE.
  • each of the slots 61 has a depth in the radial direction of the stator core 60 .
  • the total number of the slots 61 provided in the stator core 60 is equal to 48 (i.e., 8 ⁇ 3 ⁇ 2).
  • the stator core 60 is made up of, for example, 24 stator core pieces 62 as shown in FIG. 4 .
  • Each of the stator core pieces 62 defines therein one of the slots 61 .
  • each circumferentially-adjacent pair of the stator core pieces 62 together defines one of the slots 61 therebetween, More specifically, each of the stator core pieces 62 has a pair of tooth portions 63 each extending radially inward and a back core portion 64 that is provided radially outward of the tooth portions 62 to connect them together. After assembly of the stator core 60 , all of the back core portions 64 of the stator core pieces 62 are disposed to adjoin one another in the circumferential direction of the stator core 60 .
  • each of the stator core pieces 62 is formed by laminating a plurality of magnetic steel sheets with a plurality of insulting films interposed therebetween. It should be noted that other conventional metal sheets may also be used instead of the magnetic steel sheets.
  • the stator coil 70 is manufactured by stacking a plurality of wave-shaped electric wires 80 as shown in FIG. 5A-5C to form a flat band-shaped electric wire assembly 71 as shown in FIG. 14C and rolling the flat band-shaped electric wire assembly 71 by a predetermined number of turns into a hollow cylindrical shape.
  • the manufacturing method of the stator coil 70 according to the present embodiment will be described in detail later.
  • Each of the electric wires 80 for forming the stator coil 70 is configured with, as shown in FIG. 9A , an electric conductor 87 and an insulating coat 88 that covers the surface of the electric conductor 87 .
  • the electric conductor 87 is made of copper and has a rectangular cross section. With the rectangular cross section, it is possible to mount the electric wires 80 on the stator core 60 at high density.
  • the insulating coat 88 is two-layer structured to include an inner layer 88 a and an outer layer 88 b .
  • the thickness of the insulating coat 88 i.e., the sum of thicknesses of the inner and outer layers 88 a and 88 b ) is set to be in the range of 100 to 200 ⁇ m.
  • the outer layer 88 b is made of an insulating material such as nylon.
  • the inner layer 88 a is made of an insulating material having a higher glass transition temperature than the outer layer 88 b , such as a thermoplastic resin or a polyamide-imide resin. Consequently, the outer layer 88 b will be softened by the heat generated by operation of the dynamoelectric machine 100 earlier than the inner layer 88 a , thereby bonding together those portions of the electric wires 80 which are inserted in the same ones of the slots 61 of the stator core 60 . As a result, those portions of the electric wires 80 will be integrated into a rigid body, thereby enhancing the mechanical strength thereof.
  • the outer layer 88 b will be separated from the inner layer 88 a , thereby leaving the inner layer 88 a to keep covering the surface of the electric conductor 87 . As a result, the electrical insulation between the electric wires 80 can be secured.
  • each of the electric wires 80 may further include a fusible coat 89 to cover the outer surface of the insulating coat 88 ;
  • the fusible coat 89 may be made, for example, of epoxy resin.
  • the fusible coats 89 of the electric wires 80 will be fused by the heat generated by operation of the dynamoelectric machine 100 earlier than the insulating coat 88 , thereby bonding together those portions of the electric wires 80 which are inserted in the same ones of the slots 61 of the stator core 60 .
  • the insulating coat 88 may also be made of PPS (polyphenylene sulfide) to have a single layer structure.
  • FIGS. 5A-5C show one of the electric wires 80 before it is mounted to the stator core 60 to make up the stator coil 70 . It should be noted that all of the electric wires 80 are identical to each other in the present embodiment. Therefore, for the sake of avoiding redundancy, only the structure of one of the electric wires 80 will be described hereinafter.
  • the electric wire 80 is wave-shaped to include a plurality of in-slot portions 81 , each of which is to be received in one of the slots 61 of the stator core 60 , and a plurality of connecting portions 82 each of which connects one adjacent pair of the in-slot portions 81 and is to be located outside of the slots 61 of the stator core 60 .
  • the in-slot portions 81 are arranged at predetermined intervals in the longitudinal direction of the electric wire 80 and extend straight in parallel with each other.
  • Each of the connecting portions 82 includes an apex part 84 which is to be located axially furthest in the connecting portion 82 from the corresponding axial end face of the stator core 60 and extend parallel to the corresponding axial end face.
  • the apex part 84 is crank-shaped to include an oblique section 84 a that extends obliquely with respect to other parts of the connecting portion 82 on a plane perpendicular to the in-slot portions 81 of the electric wire 80 .
  • the oblique section 84 a extends obliquely with respect to a reference line L 1 with an oblique angle ⁇ between the oblique section 84 a and the reference line LI; the oblique angle ⁇ is greater than 0° and less than 90°.
  • the reference line L 1 is defined to extend radially from the axis P of the stator core 60 through the center of apex part 84 . Accordingly, the oblique section 84 a extends, in other words, obliquely with respect to the radial direction of the stator core 60 .
  • the oblique angles ⁇ of the oblique sections 84 a gradually increase from the radially inner side to the radially outer side of the stator core 60 . Consequently, all the apex parts 84 of the connecting portions 82 of the electric wires 80 together form a plurality of ridges 700 each of which extends obliquely from the radially inner side to the radially outer side of the stator core 60 in a slow curve. It should be noted that for the sake of simplicity, only one of the ridges 700 is indicated with a solid line in FIG. 8 .
  • the coolant can smoothly flow from the radially inner side to the radially outer side of the stator core 60 along the valleys formed between the ridges 700 , thereby effectively cooling both the stator coil 70 and the stator core 60 .
  • the oblique angles ⁇ of the oblique sections 84 a of the electric wires 80 which fall on the same circle are equal to each other. Consequently, it is possible to uniformize the cooling effect in the circumferential direction of the stator core 60 on both the axial end faces of the stator coil 70 .
  • the electric wire 80 is so shaped that with respect to the longitudinal axis L 2 of the electric wire 80 , all of the oblique sections 84 a of the apex parts 84 of the connecting portions 82 oblique (or slant) in the same direction. More specifically, with respect to the longitudinal axis L 2 , the oblique sections 84 a of the apex parts 84 of the connecting portions 82 on the front side (i.e., the lower side in FIG. 5B ) are oblique in the same direction as those on the rear side (i.e., the upper side in FIG. 5B ).
  • the flat band-shaped electric wire assembly is manufactured by using, for example, electric wires 90 as shown FIGS. 7A-7C .
  • Each of the electric wires 90 is so shaped that with respect to the longitudinal direction L 3 of the electric wire 90 , the oblique sections 94 a of the apex parts 94 of the connecting portions 92 on the front side (i.e., the lower side in FIG. 7B ) are oblique in the opposite direction to those on the rear side (i.e., the upper side in FIG. 7B ).
  • the change in radial position of the electric wire 80 caused by one of the oblique sections 84 a of the apex parts 84 of the connecting portions 82 is substantially equal to the thickness of the electric wire 80 . Consequently, each radially-adjacent pair of the connecting portions 82 of the electric wires 80 can be brought into contact with each other. As a result, the radial width of the coil ends of the stator coil 70 can be minimized, thereby preventing the stator coil 70 from radially protruding from the stator core 60 .
  • each of the connecting portions 82 includes a pair of shoulder parts 85 which are respectively adjacent to the pair of in-slot portions 81 connected by the connecting portion 82 and both extend perpendicular to the in-slot portions 81 (or parallel to the corresponding axial end face of the stator core 70 ). Consequently, with the shoulder parts 85 , the height of each of the connecting portions 82 (i.e., the axial length of the coil ends of the stator coil 70 ) can be reduced.
  • d1 is the length of each of the shoulder parts 85 of the connecting portions 82 of the electric wires 80 as shown in FIG. 6
  • d2 is the distance between each circumferentially-adjacent pair of the slots 61 of the stator core 60 as shown in FIG. 3 .
  • each of the connecting portions 82 of the electric wires 80 further includes two shoulder parts 86 between the apex part 84 and each of the shoulder parts 85 .
  • each of the connecting portions 82 of the electric wires 80 includes a total of seven parts, i.e., one apex part 84 and six shoulder parts 85 and 86 .
  • Each of the shoulder parts 86 extends, like the shoulder parts 85 , perpendicular to the in-slot portions 81 (or parallel to the corresponding axial end face of the stator core 70 ). Consequently, with the shoulder parts 86 , the height of each of the connecting portions 82 (i.e., the axial length of the coil ends of the stator coil 70 ) can be further reduced.
  • each of the connecting portions 82 can be seen as being stepped on both sides of the apex part 84 to reduce the height thereof.
  • the stator coil 70 is made up of six phase windings U 1 , U 2 , V 1 , V 2 , W 1 , and W 2 .
  • the phase windings U 1 and U 2 are connected in parallel with each other to make up a U-phase winding of the stator coil 70 .
  • the phase windings V 1 and V 2 are connected in parallel with each other to make up a V-phase winding of the stator coil 70 .
  • the phase windings W 1 and W 2 are connected in parallel with each other to make up a W-phase winding of the stator coil 70 .
  • the U-phase, V-phase, and W-phase windings are Y-connected to have a neutral point O therebetween.
  • each of the six phase windings U 1 , U 2 , V 1 , V 2 , W 1 , and W 2 of the stator coil 70 is formed by joining a pair of the electric wires 80 by, for example, welding. Accordingly, the number of the electric wires 80 used for forming the stator coil 70 is equal to 12.
  • Each of the electric wires 80 is wave-wound around the stator core 60 so as to extend in the circumferential direction of the stator core 60 .
  • the slots 61 of the stator core 60 are divided into eight groups each of which includes six circumferentially-adjacent slots 61 .
  • all of the in-slot portions 81 of the electric wire 80 are received in eight slots 61 that belong respectively to the eight groups and are spaced five slots 61 apart in the circumferential direction of the stator core 60 .
  • each of the connecting portions 82 of the electric wire 80 protrudes from one of the axial end faces of the stator core 60 to connect one circumferentially-adjacent pair of the in-slot portions 81 of the electric wire 80 . Consequently, all of the connecting portions 82 of the electric wires 80 together make up the coil ends of the stator coil 70 .
  • each of the electric wires 80 one end of the electric wire 80 protrudes from a most radially outer part of one of the slots 61 of the stator core 60 ; the other end of the electric wire 80 protrudes from a most radially inner part of another one of the slots 61 of the stator core 60 . Further, both the ends of the electric wire 80 protrude from the same axial end face of the stator core 60 .
  • Each of the slots 61 of the stator core 60 receives the in-slot portions 81 of only two of the electric wires 80 . Further, in each of the slots 61 , the in-slot portions 81 of one of the two electric wires 80 are alternately arranged with those of the other electric wire 80 in the radial direction of the stator core 60 .
  • the ends of the phase winding U 1 are respectively joined, for example by welding, to the ends of the phase winding U 2 , forming joining portions 75 .
  • the ends of the phase winding V 1 are respectively joined, for example by welding, to the ends of the phase winding V 2 , forming joining portions 75 .
  • the ends of the phase winding W 1 are respectively joined, for example by welding, to the ends of the phase winding W 2 , forming joining portions 75 .
  • all of the joining portions 75 are so formed as to protrude from one of the coil end of the stator coil 70 .
  • stator 50 After having described the overall configuration of the dynamoelectric machine 100 and the detailed configuration of the stator 50 , the method of manufacturing the stator 50 according to the present embodiment will be described hereinafter.
  • the method of manufacturing the stator 50 includes an electric wire-shaping step, an electric wire assembly-forming step, a stator coil-forming step, and a stator-assembling step.
  • twelve straight electric wires are shaped, using a shaping machine (not shown), to form the twelve wave-shaped electric wires 80 as shown in FIGS. 5A-5C .
  • the twelve wave-shaped electric wires 80 are sequentially stacked, as shown in FIGS. 11A-14C , to form the flat band-shaped electric wire assembly 71 .
  • the electric wires 80 are so stacked as to be deviated from one another in the longitudinal direction of the electric wire assembly 71 by the distance d2 between each circumferentially-adjacent pair of the slots 61 of the stator core 60 .
  • the reference numerals 1 to 12 represent the numbers of the electric wires 80 in the sequential stacking thereof.
  • the flat band-shaped electric wire assembly 71 is rolled, around a cylindrical core member having a predetermined outer diameter (not shown), by a predetermined number of turns (e.g., five turns in the present embodiment) into a hollow cylindrical shape. Further, in this step, the corresponding ends of the electric wires 80 are joined together by, for example, welding. As a result, the stator coil 70 is obtained which has a hollow cylindrical shape as can be seen from FIG. 2 .
  • the stator core 60 is assembled to the stator coil 70 , thereby forming the stator 50 .
  • the stator core 60 is made up of 24 stator core pieces 62 as shown in FIG. 4 .
  • the stator core pieces 62 are so mounted to the stator coil 70 that the tooth portions 63 of the stator core pieces 62 are respectively inserted into the spaces formed between circumferentially-adjacent pairs of the in-slot portions 81 of the electric wires 80 .
  • all of the back core portions 64 of the stator core pieces 62 are joined to one another by, for example, welding.
  • the stator 50 is obtained which is shown FIG. 2 .
  • stator coil 70 is formed with the single flat band-shaped electric wire assembly 71 , it is possible to minimize the number of the joining portions 75 which join the ends of the electric wires 80 , thereby minimizing the size of the stator coil 70 .
  • the coolant is discharged by the coolant supplier via the coolant discharge outlets 23 a . Then, the coolant, which has been discharged to the coil ends (i.e., the connecting portions 82 of the electric wires 80 ) of the stator coil 70 , further flows along the radially outer surfaces of the coil ends, thereby spreading over the entire stator coil 70 . On the other hand, the coolant, which has flowed to the axial end faces of the rotor 40 , further flows radially outward with rotation of the rotor 40 , passing the coil ends of the stator coil 70 .
  • the coolant which has flowed to the axial end faces of the rotor 40 , further flows radially outward with rotation of the rotor 40 , passing the coil ends of the stator coil 70 .
  • the rotating direction of the rotor 40 and thus the flow direction of the coolant can be made, on both the axial end faces of the coil ends of the stator coil 70 , coincident with the extending directions of the ridges 700 which are made up of the apexes 84 of the connecting portions 82 of the electric wires 80 .
  • the ridges 700 are indicated with a solid line in each of FIGS. 15A and 158 . Consequently, the coolant can smoothly flow along both the axial end faces of the coil ends of the stator coil 70 , thereby effectively cooling both the coil ends.
  • This embodiment illustrates a method of manufacturing a stator for the dynamoelectric machine 100 , which is different from the method according to the previous embodiment.
  • the method according to the present embodiment also includes an electric wire-shaping step, an electric wire assembly-forming step, a stator coil-forming step, and a stator-assembling step.
  • a total of 48 straight electric wires are shaped, using a shaping machine (not shown), to form four groups of wave-shaped electric wires 80 as shown in FIGS. 5A-5C .
  • Each of the four groups includes twelve electric wires 80 . All of the electric wires 80 in the same group have the same length. However, the electric wires 80 in different groups have different lengths.
  • the twelve wave-shaped electric wires 80 of each of the four groups are sequentially stacked, as shown in FIGS. 11A-14C , to form a flat band-shaped electric wire assembly.
  • four flat band-shaped electric wire assemblies 71 a , 71 b , 71 c , and 71 d (not shown) are obtained which have different lengths.
  • each of the four flat band-shaped electric wire assemblies 71 a - 71 d is rolled, around a cylindrical core member having a predetermined outer diameter (not shown), by a single turn.
  • four hollow cylindrical electric wire assemblies 77 a , 77 b , 77 c , and 77 d are obtained which have different inner and outer diameters as shown in FIGS. 16A-16D .
  • the outer diameter of the assembly 77 a is substantially equal to the inner diameter of the assembly 77 b ;
  • the outer diameter of the assembly 77 b is substantially equal to the inner diameter of the assembly 77 c ;
  • the outer diameter of the assembly 77 c is substantially equal to the inner diameter of the assembly 77 d.
  • the four hollow cylindrical electric wire assemblies 77 a - 77 d are assembled together, more specifically radially staked together, forming a stator coil 76 as shown in FIG. 17 .
  • the corresponding ends of the electric wires 80 are joined together by, for example, welding.
  • stator core 60 is assembled to the stator coil 76 , in the same way as in the previous embodiment, thereby forming the stator 50 according to the present embodiment.
  • the stator coil 76 is formed by radially stacking the hollow cylindrical electric wire assemblies 77 a - 77 d which have different inner and outer diameters. Further, the hollow cylindrical electric wire assemblies 77 a - 77 d are respectively formed by rolling the flat band-shaped electric wire assemblies 71 a - 71 d which have different lengths. Furthermore, the four flat band-shaped electric wire assemblies 71 a - 71 d are respectively formed by using the four groups of the electric wires 80 having different lengths.
  • the lengths of all the electric wires 80 and the lengths of all the flat band-shaped electric wire assemblies 71 a - 71 d are considerably shortened compared to the length of all the electric wires 80 and the length of the single flat band-shaped electric wire assembly 71 in the previous embodiment.

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  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Windings For Motors And Generators (AREA)
  • Manufacture Of Motors, Generators (AREA)
US12/613,782 2008-11-07 2009-11-06 Stator for dynamoelectric machine and method of manufacturing same Active 2030-09-08 US8179013B2 (en)

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JP2008286181A JP5453770B2 (ja) 2008-11-07 2008-11-07 回転電機の固定子およびその製造方法

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JP5674012B2 (ja) * 2010-10-07 2015-02-18 株式会社デンソー 回転電機の固定子およびその製造方法
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JP5716505B2 (ja) * 2011-04-07 2015-05-13 株式会社デンソー 回転電機の固定子
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JP6089593B2 (ja) * 2012-10-31 2017-03-08 アイシン精機株式会社 ３相回転電機の波巻き巻線
JP6135535B2 (ja) * 2014-02-07 2017-05-31 株式会社デンソー 回転電機の固定子
JP6394973B2 (ja) * 2015-02-19 2018-09-26 株式会社デンソー 回転電機
JP6394971B2 (ja) 2015-02-19 2018-09-26 株式会社デンソー 回転電機の固定子
JP6394972B2 (ja) 2015-02-19 2018-09-26 株式会社デンソー 回転電機の固定子
JP6410104B2 (ja) 2015-07-31 2018-10-24 株式会社デンソー 回転電機の固定子及びその固定子を備えた回転電機
WO2018216168A1 (ja) 2017-05-25 2018-11-29 三菱電機株式会社 電動機、圧縮機および空気調和装置
DE102020210454A1 (de) 2019-08-27 2021-05-12 Motional AD LLC (n.d.Ges.d. Staates Delaware) Kühllösungen für autonome Fahrzeuge
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CN101902084A (zh) 2010-12-01
JP5453770B2 (ja) 2014-03-26
DE102009044459A1 (de) 2010-05-27
JP2010115031A (ja) 2010-05-20
CN101902084B (zh) 2013-01-30
US20100117480A1 (en) 2010-05-13
DE102009044459B4 (de) 2019-09-05

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